CHEMCADTutorials

170 CHEMCADVersion6UserGuide
Piping Tutorial
Apipingnetworkrepresentstheflowoffluidsthroughseveralpiecesofequipment.
Ifsufficientvariables(flowrateandpressure)arespecifiedonthepipingnetwork,
CHEMCADcalculatestheunknownvariables.
Forfluidflowthroughequipment,flowratemaybecalculatedasafunctionof
[Link],
CHEMCADcancalculatethethird.
Inthistutorial,[Link]
performcontrolvalveandorificesizingandrating;simulatecomplexpiping
networks;usefeedbackcontrollers;calculateNPSH;andmakeappropriate
equipmentselections.
Control Valve Sizing Example
Thisportionofthepipingtutorialcoverscontrolvalvesizing,controlvalves,andthe
useofnodes.
Problem Statement
Forthispartofthetutorial,[Link]
exampleiscalledExample1,anditslocatedintheMy
Simulations\Examples\Pipingfolder.
D-1
-9F
225 psig
D-2
-1F
15 psig
D-3
-28F
0.2 psig

Figure 11-48: Diagram of control valve sizing example

Youneedtosizecontrolvalvesforhandlingaflowof113,000lb/hrofliquid
[Link]
andthendeterminethepercentopenforeachvalveattheratedservice.
Toperformtheinitialsizing,allyouneedarestreamswiththecorrectproperties
(seeFigure1149).Itisnotnecessarytomodelthetanks.
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1
1 2
3

Figure 11-49: Streams for initial sizing

AllthreestreamsinFigure1149areattheinletconditionsof9Fand225psig.
Thedividersplitsthe226,000lb/hrflowintotwoequalflowsof113,000lb/hrof
ammonia.
Toperformtheinitialsizing,followthesesteps:
1. ClicktheRunAllbuttononthemainCHEMCADtoolbartocalculatethe
flowinformationforstreams2and3.Bothstreamsshouldbeat9F,225
psig,and113,000lb/hrofammonia.
2. [Link]
[Link]>ControlValvetobringuptheControlValve
Sizingdialogbox.

Figure 11-50: The Control Valve Sizing dialog box

3. IntheDownstreampressurefield,[Link]
[Link]
ofthestreamandthecalculatedparametersforthevalve.
4. Repeattheprocedureforstream3,usingadownstreampressureof0.2psig.
Rating Case
[Link]
positionforthesevalvesinthisserviceat113,000lb/[Link]
behaviorofthecontrolvalves,youwillneedaslightlylargerflowsheet,asshownin
Figure1151.
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172 CHEMCADVersion6UserGuide
1
2
3
1
4
5
6
7
4
8
3
5
9
2

Figure 11-51: Flowsheet for rating valves in a simulation

TheflashUnitOpsattheendarenotnecessary;theyareincludedtoillustratethe
vaporandliquidflowratesinseparatestreamsifflashingoccurs.
Thedividerisstillsetto113,000lb/hr,andtheflashtanksaresettothemode
calledSpecifyTandP;calculateV/[Link]#2issetto1Fand15
[Link]#3issetto28Fand0.2psig.
Followthesestepstoratethecontrolvalves:
1. Doubleclicktheiconforcontrolvalve#4toopentheControlValvedialog
box.

Figure 11-52: The Control Valve dialog box

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2. IntheValveflowcoefficient(Cv)field,[Link]
pressurefield,[Link]
flowrate,[Link].
3. Nowdoubleclicktheiconforcontrolvalve#[Link],selectthesame
operatingmodethatyouusedforvalve#[Link]
54andadownstreampressureof0.2psig,andthenclickOK.
4. ClicktheRunAllbuttononthetoolbartorunthesimulation.
5. Toviewtheresults,firstclickablankareaoftheCHEMCADworkspaceto
[Link]>UnitOps
>SelectUnitOps.
6. IntheSelectUnitOpsdialogbox,type4,press[RETURN],andthentype5.
ClickOKtobringupareportforthesetwovalves.
Thereportshowsthatvalve#4isat72.5%open,andvalve#5isat53.3%open.
Toseehowmuchvaporizationoccursacrossvalve#5,rightclickthevalveand
[Link]
[Link],a
smallertwoinchvalvebodywouldbeapproachingsonicvelocitythroughthevalve
body.
Flow Rate as a Function of Pressure
IntypicalCHEMCADsimulations,informationflowsinonedirection:downstream.
[Link],
[Link]
eithercalculatedbasedonfloworspecifiedthroughUnitOps,andthedownstream
pressures,flowrates,andsofortharecalculatedwhenyourunthesimulation.
Forpipingsimulations,[Link]
backpressureonvalves,pipes,andotherUnitOpsaffectstheflowratethroughthe
[Link],theflowratethroughavalve(orthroughapipeorapump)
determinesthedownstreampressure.
Inflowmodelslikethecontrolvalvesizingmodel,itissometimesusefultolet
[Link],supposeaprocessupsetin
thesystemshowninFigure1153causedthepressureinvesselD2torisefrom15
[Link],whatisthe
newflowratefromD1?
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174 CHEMCADVersion6UserGuide
D-1
-9 F
225 psig
D-2
-1 F
30 psig (UPSETcondition)
D-3
-28F
0.2 psig
Cv=36
72.5 % open
Cv=54
53.3% open

Figure 11-53: Vessel D-2 in an upset condition

Toanswerthisquestion,[Link]
pointinthesimulationthathasapressure,aflowcomingin,andaflowgoingout.
Thenodeunitscreateanetwork,solvingforflowrateateachpointbasedonthe
[Link]
downstreamfromeachcontrolvalve.Figure1154showsthesystemwithnodesin
place.
6
7
8
9
10
10 11
12
13
14
11
15
18
12
16
19
20
17

Figure 11-54: Nodes located upstream and downstream from control valves
Thefunctionofthedividertosplittheincomingflowisnowhandledbynode
#[Link]
[Link]
[Link],andlettheflowratevary
asafunctionofvalvepositionandpressuredifference.
Toseehowthesenodesaresetup,youcandoubleclicknode#6toopenthe
Nodedialogbox.
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Figure 11-55: The Node dialog box

[Link]
stream,[Link]
controlvalvewillbedeterminedbythecontrolvalveopeningpositionandthe
pressuredifferenceacrossthevalve.
Fornode#9,thefixedpressureissetto30psig,andfornode#10,thepressureis
[Link]
FlowsetbyUnitOpmode;flowoutissettoFreeOutletstream.
Thecontrolvalvesneedtobechangedtofixthevalvepositionandcalculateflow
[Link],settheOperatingmodeforeachvalvetoFixvalveposition,adjust
flowrate.
Aftermakingthischange,clicktheRunAlltoolbarbuttontorunthesimulation.
Afterrunning,youcanviewthestreamsaroundnode#6byrightclickingthenode
[Link](Figure1156)shows
thattheflowrateforstream11(upstreamfromD2)hasdroppedfrom113,000lb/hr
to109,138lb/[Link]
thevalves.

Figure 11-56: Stream composition report for node #6

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Simple Flow Example
Thisportionofthepipingtutorialcoverscontrolvalvesizing,feedbackcontrollers,
NPSH,orificesizing/rating,pipesizing/rating,andthePipeUnitOp.
Problem Statement
Thepipingsystemshownmustbedesignedtotransport120gpmofglacialacetic
acidat70140F.Thepressureattheinletisknownat20psia,andtheoutletmustbe
[Link]
[Link]
theNPSHaandheadrequirementsforfuturepumpselection.

Figure 11-57: Piping isometric for this problem

ThisexampleiscalledExample2,anditslocatedinthelocatedintheMy
Simulations\Examples\Pipingfolder.
Creating the Simulation
Followthesestepstocreateandrunthissimulation:
1. [Link]
UnitOpsareusedtorepresententiresectionsofpiping,includingfittings:
2. SelectSizing>PipingandselecttheapplicablestreamstobringupthePipe
Sizingdialogbox.
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Figure 11-58: The Pipe Sizing dialog box

3. SelecttheTypicalsizingforsinglephaseoptionandusestandardschedule
[Link].
Note:Sincethefluidinthissystemissubcooledliquidandallflowsareconstant,
[Link]
pumpsuctionpipe,whichasageneralruleshouldbeonesizelarger.
4. SelectSizing>Orificeandselectthestreamonthedischargesideofthe
[Link],selectDandD/2pressuretaps,enter
3asthepipeinsidediameter,andenter100asthewaterdifferentialpressure.
ClickOKtobringupanorificesizingreportfortheselectedstream.
Note:Usingthecalculatedborehole,CHEMCADdeterminestheflowresistance
factoroftheorificeasshown:
) 1 ( /(
4
=
d
C C
4 2
2
1

C
Kr


TheorificesizingreportgivestheKrvalue,whichyouwilluselaterinthePipe
SizingandRatingdialogbox.
5. Tosizethecontrolvalve,selectstream#1andthenselectSizing>Control
[Link],enter15,andselecttheSingleseat
[Link]#1isat20psia,youaresimplysizingacontrolvalveto
[Link]
reportfortheselectedstream.
6. Doubleclickcontrolvalve#[Link]
valveflowcoefficient(Cv)ofthevalvefromthesizingreport,setthevalve
positionto50%,andsettheoperatingmodetoFixflowandposition,
[Link].
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178 CHEMCADVersion6UserGuide
7. DoubleclicktheheatexchangericontoopentheSimpleHeatExchanger
dialogbox.Enterapressuredropof2psiandsettheoutlettemperatureto
[Link].
8. Tabulateandspecifythevalves,fittings,pipelengths,andelevationchanges
[Link],settheMethodfieldto2Single
Phaseflow,settheSizingoptionto0Rating,anduseflangedfittings
throughout.
Pipe#1
1entrance,wellrounded
2ballvalves
4standardelbows,90degree
1tee,flowthroughbranch
35feetofpiping
8elevationchange

Pipe#3(beforecontrolvalve)
1swingcheckvalve,clearway
2ballvalves
2tee,flowthroughrun
1orificeplate(aspreviouslydetermined)
14feetofpiping
14elevationchange

Pipe#5(aftercontrolvalve)
2ballvalves
2tee,flowthroughrun
3standardelbows,90degree
1exitfrompipe
24feetofpiping
2footelevationchange

Pipe#7(afterE1515)
1ballvalve
4standardelbows,90degree
1tee,flowthroughrun
1wellroundedentrance
1exitfrompipe
157feetofpiping
5elevationchange

9. Specifythepumpoutletpressureatsomearbitraryvalue(try25psia)and
[Link]
findtherequiredpumphead.
Using Controllers to Simplify the Problem
Whilemanuallychangingthepumpoutletpressurewillgetyouwhereyouneedto
be,[Link]
pressureforyou.
AfeedbackcontrollerinCHEMCADhasnothingtodowithprocesscontrol
[Link],thetermfeedbackcontrol
[Link]
flowsheetuntilatargetvaluereachesaspecifiedvalue.
Followthesestepstouseafeedbackcontrollertocalculatetherequiredoutlet
pressure:
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CHEMCADVersion6UserGuide 179
1. Rightclickstream#[Link]
andthenclicktheControllertoolintheAllUnitOpspalette.
2. [Link]
streamautomaticallyreroutesthroughthisicon,asshowninFigure1159.
7
7
8
8
9

Figure 11-59: Insertion of feedback controller

3. IntheControllerdialogbox,specifythefollowingandthenclickOK:
Controllermode:Feedbackward
Adjustthisvariable:Unitop,IDnumber2,Variable2Outputpressure
Untilthis:Stream,IDnumber8,Variable2Pressure
Isequaltothistarget:Constant20,Units4Pressure
Whenyourunthesimulation,thecontrollerwillautomaticallychangethepump
[Link]
nowknowtheheadrequirementsforyourpump.
Calculating NPSHA
Thenetpositivesuctionhead,betterknownasNPSH,isdefinedasthetotalpressure
[Link]
alwaysreportedinfeetofpumpedfluidorwater.
EverypumphasaspecifiedNPSHrequirement(NPSHr)atagivenoperating
[Link],theavailableNPSH(NPSHa)mustbegreater
[Link],cavitationandshortenedservicelifemayresult.
Toselecttheappropriatepump,[Link],
[Link],
[Link],the
calculatedNPSHaisdisplayed.
Note:ItisimportanttotheNPSHacalculationthattheinletpipingtothepumpbe
[Link],thepressureatthe
inletmaynotbeaccurate,leadingtoaninaccurateNPSHacalculation
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Branched Flow Example
ThisportionofthepipingtutorialcoverstheNodeUnitOp,pipenetworks,pump
selectioncriteria,andPumpUnitOpperformancecurves.
Problem Statement
[Link]
heatexchangers,theproblemisnolongerasimpleone.

Figure 11-60: Piping isometric showing branched flow

ThisexampleiscalledExample3,anditslocatedinthelocatedintheMy
Simulations\Examples\Pipingfolder.
Thebranchedflowisadifficultproblemtosolveusingthecontrollerapproach.
[Link]
anapproachwhereyousplitandrecombineflows,andhavethesimulationcalculate
[Link]
flexibility.
[Link]
[Link]
[Link]
vary.
Creating the Simulation
ConvertthepipingisometrictoaCHEMCADflowsheet,asshowninFigure1161.
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Figure 11-61: The flowsheet representing this piping system

InCHEMCAD,PipeUnitOpsareusedtorepresententiresectionsofpiping,
[Link]
unknown.
Forthisexample,assumeapressuredropof2psiacrosseachheatexchanger.
Tabulatethevalves,fittings,pipelengths,andelevationchangesofeachsectionof
[Link].
Pipe#1
1entrance,wellrounded
2ballvalves
4standardelbows,90degree
1tee,flowthroughbranch
35feetofpiping

Pipe#2(beforecontrolvalve)
1swingcheckvalve,clearway
2ballvalves
2tee,flowthroughrun
1orificeplate(asdeterminedabove)
14feetofpiping

Pipe#3(aftercontrolvalve)
1ballvalve
1tee,flowthroughrun
2standardelbows,90degree
10feetofpiping
Pipe#4(toE1514)
1tee,flowthroughbranch
1ballvalve
1exitfrompipe
3standardelbows,90degree
26feetofpiping
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Pipe#5(fromE1514)
1ballvalve
1wellroundedentrance
3standardelbows,90degree
1tee,flowthroughbranch
30feetofpiping
Pipe#6(toE1515)
1ballvalve
1exitfrompipe
1tee,flowthroughrun
1standardelbows,90degree
14feetofpiping

Pipe#7(fromE1515)
1standardelbow,90degree
1ballvalve
1wellroundedentrance
1tee,flowthroughrun
10feetofpiping
Pipe#8(toV1522)
3standardelbows,90degree
1exitfrompipe
147feetofpiping

Atthistimeyoudontknowthepumpspecifications,sosetthepumptoSpecify
[Link]
solveforthepressureincrease,andsetthepumpoutletpressureaccordingly.
Setupthenodeswiththefollowinginformation:
Node3:Variablepressure,usecurrentstreamrateforinlet,flowsetby
UnitOpforoutlet,elevation=20feet
Node5:Variablepressure,flowsetbyUnitOpforbothinletandoutlet,
elevation=34feet
Node7:Variablepressure,flowsetbyUnitOpforbothinletandoutlet,
elevation=34feet
Node9:Variablepressure,flowsetbyUnitOpforbothinletandoutlet,
elevation=34feet
Node12:Variablepressure,flowsetbyUnitOpforbothinletandoutlet,
elevation=50feet
Node16:Variablepressure,flowsetbyUnitOpforbothinletandoutlet,
elevation=38feet
Node18:Variablepressure,flowsetbyUnitOpforbothinletandoutlet,
elevation=42feet
Node20(lastnode):Fixedpressure,20psia,flowsetbyUnitOpforinlet,free
outletstreamforoutlet,elevation=43feet
Running the Simulation
Torunthesimulation,clicktheRunAllbuttononthemainCHEMCADtoolbar.
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CHEMCADVersion6UserGuide 183
Oncethesimulationhasrun,[Link]
[Link]
rate(120gpm),youcanconsultapumphandbooktodeterminethecorrectpump
size.
Selecting a Pump
Thefollowingpumpcurvedataisrepresentativeofthetypeofequipmentthat
wouldbeappropriateforthisapplication.
Pump Curve
1750 rpm
1450 rpm
1150 rpm
20
30
40
50
60
70
80
90
0 40 80 120 160 200
Flow (gpm)
H
e
a
d

(
f
t
)

1750 rpm
1450 rpm
1150 rpm
0.3
0.35
0.4
0.45
0.5
0.55
0.6
0 40 80 120 160 200
Flow (gpm)
E
f
f
i
c
i
e
n
c
y

Figure 11-62: Combined pump curves for a sample pump

Toenterthiscurveintoyourpump,openthePumpdialogboxandselect
[Link]
[Link],enter1
[Link]
bringupthePerformanceCurvedialogbox.
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184 CHEMCADVersion6UserGuide

Figure 11-63: The Performance Curve dialog box

Hereyoucanenterasmanypointsasyouwanttodefineyourcurve.
CHEMCADwillfitaquadraticequationtothepoints,creatingasmoothcurvefitfor
yourdata.
Nowthatyouhaveenteredthepumpperformancecurve,youmustaddnode
[Link],
youcancalculatethemaximumflowrateofyoursystem.